Shaping material for electrode, electrode and methods of producing and recycling same, and electrochemical device

Abstract

Provided is a shaping material for an electrode that is easy to produce, in which the proportional content of an active material is easy to improve, and with which problems of odor and stability have a low tendency to occur. The shaping material for an electrode contains at least one active material (A) and a viscous electrolyte composition. The viscous electrolyte composition contains: at least one ionic material (S); and an organic composition (P—O) containing at least one polymer (P) and a low molecular weight organic compound (O) having a molecular weight of less than 10,000. The proportional content of the polymer (P) in the organic composition (P—O) is 50 mass % or less. The proportion constituted by a compound having an equal or higher volatilization rate than N-methylpyrrolidone among the low molecular weight organic compound (O) is not less than 0 mass % and not more than 20 mass %.

The invention claimed is: 
     
       1. A shaping material for an electrode comprising: at least one active material (A); and a viscous electrolyte composition, wherein
 the viscous electrolyte composition contains: at least one ionic material(S); and an organic composition (P—O) containing at least one polymer (P) and a low molecular weight organic compound (O) having a molecular weight of less than 10,000, 
 a gel content of the polymer (P) is 20 mass % or less, 
 proportional content of the polymer (P) in the organic composition (P—O) is 50 mass % or less, 
 a proportion constituted by a compound having an equal or higher volatilization rate than N-methylpyrrolidone among the low molecular weight organic compound (O) is not less than 0 mass % and not more than 20 mass %, 
 proportional content of a compound that is a liquid at a temperature of 5° C. under atmospheric pressure in the organic composition (P—O) is not less than 0 mass % and not more than 20 mass %, and 
 the low molecular weight organic compound (O) includes at least two compounds each having a volatilization rate lower than N-methylpyrrolidone. 
 
     
     
       2. The shaping material for an electrode according to  claim 1 , further comprising a conductive filler. 
     
     
       3. The shaping material for an electrode according to  claim 1 , wherein proportional content of the active material (A) is 50 volume % or more. 
     
     
       4. The shaping material for an electrode according to  claim 1 , wherein proportional content of the active material (A) is 60 volume % or more. 
     
     
       5. The shaping material for an electrode according to  claim 1 , wherein the active material (A) is of a nanosize. 
     
     
       6. The shaping material for an electrode according to  claim 1 , further comprising a fiber component having a fiber diameter that is of a nanosize. 
     
     
       7. The shaping material for an electrode according to  claim 1 , wherein the viscous electrolyte composition has an ion conductivity at a temperature of 35° C. of 1.0×10 −4  S/cm or more. 
     
     
       8. The shaping material for an electrode according to  claim 1 , wherein the viscous electrolyte composition has an ion conductivity at a temperature of −20° C. of 1.0×10 −4  S/cm or more. 
     
     
       9. An electrode comprising a portion formed using the shaping material for an electrode according to  claim 1 . 
     
     
       10. The electrode according to  claim 9 , wherein the portion has a porosity of 20 volume % or less. 
     
     
       11. The electrode according to  claim 9 , obtained through film formation of the shaping material for an electrode in a sheet shape. 
     
     
       12. The electrode according to  claim 9 , obtained by affixing the shaping material for an electrode to a current collector. 
     
     
       13. The electrode according to  claim 12 , wherein the current collector includes a through hole at a site where the shaping material for an electrode is affixed. 
     
     
       14. The electrode according to  claim 12 , wherein the current collector has a conductive coating at a surface that is in contact with the shaping material for an electrode. 
     
     
       15. The electrode according to  claim 9 , wherein the shaping material for an electrode is cross-linked or polymerized. 
     
     
       16. A method of producing an electrode comprising a step of squashing a plurality of strands formed of the shaping material for an electrode according to  claim 1  to shape the plurality of strands into a sheet shape. 
     
     
       17. A method of producing an electrode comprising a step of performing forming of the shaping material for an electrode according to  claim 1  and subsequently affixing the shaping material for an electrode to a current collector. 
     
     
       18. A method of producing an electrode comprising a step of affixing the shaping material for an electrode according to  claim 1  to both sides of a current collector. 
     
     
       19. A method of producing an electrode comprising a step of squashing the shaping material for an electrode according to  claim 1  using a curved surface having a radius of curvature of 100 mm or less. 
     
     
       20. A method of producing an electrode comprising a step of paring the shaping material for an electrode according to  claim 1  to adjust either or both of thickness and shape. 
     
     
       21. A method of producing an electrode comprising a step of performing rough adjustment of thickness of the shaping material for an electrode according to  claim 1  and subsequently performing fine adjustment using a curved surface having a radius of curvature of 0.5 mm or more. 
     
     
       22. The method of producing an electrode according to  claim 16 , comprising a step of measuring thickness of the shaping material for an electrode and performing feedback control of basis weight of the shaping material for an electrode. 
     
     
       23. A method of recycling the electrode according to  claim 12 , comprising a step of peeling the shaping material for an electrode from the current collector. 
     
     
       24. An electrochemical device comprising the electrode according to  claim 9 . 
     
     
       25. The electrochemical device according to  claim 24 , wherein a counter electrode of the electrode is formed of at least one selected from an alkali metal, an alkaline earth metal, and metal aluminum. 
     
     
       26. The electrochemical device according to  claim 24 , wherein either or both of a counter electrode of the electrode and a separator contain an inorganic filler having moisture trapping ability. 
     
     
       27. The electrochemical device according to  claim 24 , wherein either or both of a counter electrode of the electrode and a separator contain an ionic material having moisture trapping ability.